Kraft Foods Supplier Quality and Food Safety Forum

Transcription

1 Kraft Foods Supplier Quality and Food Safety Forum Kraft Foods Supplier Quality Management Processes & Programs For Traders, Distributors and Brokers May 2012

2 Kraft Foods and Cadbury: Building a Global Powerhouse $50B in Combined Revenue, Driven by 11 $1B + Brands Presence that s global. World s second-largest food company #1 in North America #1 in confectionery and biscuit Sales in ~160 countries 25%+ of global revenue from emerging markets Over 70 $100MM+ brands 2

3 Agenda Introduction Overview Kraft Foods Quality Programs Contractual Relations and Information Exchange 5 min 5 min 15 min between Kraft Foods, Trader & Supplier Role & Responsibilities of the Broker/Distributor/Trader Kraft Foods Supplier Quality Expectations Summary Q&A Basic Requirements Key programs 10 min 20 min 5 min 30 min 3

4 The safety and quality of our products is of the highest importance Consumer Protection & Trust Consumers trust Kraft Trust begins with excellence in food safety and quality Business Survival Our people and our brands are our important assets Industry Responsibility Committed to food safety and quality across the food chain Now more than ever 4

5 Integrated Quality Chain Management Focus on Preventative Systems Applies to internal & external plants Design Procure Convert Distribute Trade Consumer Specifications HACCP Allergens Supplier QA Plant Design Plant Equipment Process Capability Supplier Quality Management SQM Policy Contracts Selection/ Approval Monitoring Continuous Improvement Specifications HACCP Allergens Supplier QA PRPS Traceability Sanitation Pest Control Environment Traceability Sanitation Pest Control Environment Warehouse Controls Complaints Warehouse Control Specification PCPS Allergens Consumer Response Complaint Handling Process Capabilities Compliant Reduction Process Control Process Capabilities 5

6 Supplier Quality Management A comprehensive approach to managing supplier quality Policy/Contract Requirements Continuous Improvement Supplier QI Program Supplier Quality Partnerships Supplier Development Supplier Forums Industry Benchmarking Quality Policy WW Supplier Quality Expectations (SQE) Supplier HACCP Manual Material Specifications Selection/Approval Risk Assessments Supplier Pre-Assessment Quality Audit Approval WW Quality Audit Program Materials Monitoring Program COA Verification Supplier Performance Monitoring Certificate of Conformance (COC) 6 Monitoring

7 The bottom line All materials that are delivered to Kraft Foods must have been produced 1) at a Kraft Foods approved manufacturing site and 2) according to Kraft Foods Specification 7

8 8 Contractual Relationships and Information Exchange between Kraft Foods, Trader & Supplier

9 Key Principle: Sourcing from approved supplier ONLY PRODUCING SITE A KRAFT Kraft General Terms & Conditions obligation to meet quality requirements right for Kraft to audit facilities of suppliers NOT APPROVED TRADER Trader s Terms & Conditions Trader s Terms & Conditions PRODUCING SITE B PRODUCING SITE C PRODUCING SITE D APPROVED 9

10 Trader is contractually liable for default of supplier DAMAGES Kraft General Terms & Conditions KRAFT TRADER SUPPLIER A obligation to meet quality requirements right for Kraft to audit facilities of suppliers Trader is liable Supply of defective products 10

11 Direct flow of information regarding quality between Kraft and Supplier Direct continuous and timely flow of information MITIGATING LOSS Kraft General Terms & Conditions KRAFT TRADER SUPPLIER A obligation to meet quality requirements right for Kraft to audit facilities of suppliers Trader s Terms & Conditions obligation of Supplier continuously and timely inform Kraft directly about quality issues 11 Direct continuous and timely flow of information

12 12 General terms & conditions of purchase as basis for a successful e-bidding

13 Principle: Kraft s terms apply to supply of goods Kraft Foods General Terms & Conditions TRADER Trader s Terms & Conditions KRAFT Kraft Foods General Terms & Conditions SUPPLIER Supplier s terms & conditions Any deviation to this principle can only be valid and binding upon Kraft Foods if agreed and acknowledged by Kraft in writing with signature 13

14 Application of principle to e-bidding process INFORM KRAFT general terms and conditions for the e-bidding process KRAFT general terms and conditions for the supply of goods (accessible on a website to which each Purchase Order is linked) KRAFT ACCEPT Acceptation of Kraft general terms and conditions is a pre requisite You can word material issues but too many issues raised may lead to disqualification and need to be clarified before participation SUPPLIER TRADER PARTICIPATE All supply of goods deriving from successful e-bidding Are subject to Kraft general terms and conditions for the supply of goods as accepted under step 2 SUPPLIER TRADER 14

15 15 Roles & Responsibilities of the Trader/Broker/Distributor

16 Roles & Responsibilities The Broker/Distributor/Trader must ensure that any materials delivered to Kraft Foods are produced in a Manufacturing site approved by Kraft Foods. Brokers, Distributors and Traders must ensure all Kraft Foods Supplier Quality Documents are communicated to all their suppliers supplying to Kraft Foods and provide evidence of the communication to Kraft Foods. The Broker/Distributor/Trader must ensure all necessary documents are provided to Kraft Foods. For example; Testing of product shipped is done in accordance to KF requirements (parameters, sample size, testing labs etc.) Kraft factories are receiving the CoA as per requirements The Broker/Distributor/Trader is required to notify Kraft Foods Contract Representative of any manufacturing location changes. New sites must be approved by Kraft Foods prior to use. The Broker/Distributor/Trader is required to notify the Kraft Foods Contract Representative if he handles the unpacked (i.e. naked ) material himself, e.g. re-filling from a larger/bulk into a smaller pack. 16

17 Which are the Supplier Quality Documents? SQE (including packaging) main information SQE Resource Document detailed information supplementing the base manual s requirements. Must be sent to the suppliers. Suppliers are expected to implement these requirements. Supplier/EM HACCP Manual Process Guidelines Cocoa, Dairy, Nuts, Egg, etc. Where appropriate must be sent to suppliers Documents specific to certain ingredients, that outline acceptable processing conditions. Kraft Foods Specification (Raw Material, Packaging material) Must be sent to the suppliers. Contains technical information specific to a material. SQE: Supplier Quality Expectations HACCP: Hazard Analysis and Critical Control Points 17

18 18 SQE Confirmation

19 Evidence of communication to production plant Trader/Broker to get signature from each production site Completed form to be sent back to Kraft Foods 19

20 Supplier Approval Kraft audit requirements Approval is based on the specific supplier facility having passed an audit The supplier s manufacturing site is approved, not the supplier in general. Traders must disclose the Manufacturing location The type of audit that can be accepted is based on risk analysis of the material (Tier Rating) Kraft audit mandatory for some materials The Tier determines: who will perform the audit (Kraft or 3 rd party), the types of audits & certificates which are accepted for both initial approval of the site and for ongoing audits, the audit frequency. Kraft only accept the certificates recognized by GFSI (link Food Safety Assessment: According to the supplier tier, it may be required to perform a Food Safety Assessment at the suppliers (on top of the Quality Audits). They are performed by our Microbiology group, who will determine the adequate frequency. 20

21 Kraft Foods Audit Matrix (Revised 11 May 2012) Tier Ingredient Categories (List is not all inclusive - refer to the Raw Material Tier Assignment list for details) Qualification Process (new) Accepted Audits & Certifications (ongoing) Target Freq. (years) 1 RTE Meats, Cheeses, RTE Raw Fruits/Vegetables Kraft Audit Kraft Audit 1.5 RTE Nuts/Seeds/Coconut, Retorted & Aseptic Products (Low Acid Canned Foods), Cocoa/Chocolate/Confectionary, Treated Herbs/Spices/Seasoning; 2 Tea & Tea Products; Egg & Egg Products; Dairy Products & Substitutes; Yeast; Enzymes 2 / Fruit & Fruit Products, Vegetable & Vegetable Products, Flavoring Ingredients (material assigned to tier 2 or 4 - refer to the Raw Material Tier Assignment list for details) 4 Grain & Grain Products, Emulsifiers; Prepared Sauces/Spreads/Condiments, Coffee &Coffee Products, Bread & Bakery Products; Sugars & Sweeteners; Starter Media/Culture; Fats & Oils; Food Additives; 3 Raw Meat & Raw Meat Products, Food Chemicals Hydrocolloids & Gums, Wafers; Untreated Herbs/Spices/Seasoning; ²Direct Contact Packaging Material Labeled and Unlabeled, Non-Contact Packaging Material Labeled; 6 Chemical- Distillation,Crystallization,Extraction Raw Milk & Cream, Nationally Branded Confections; Green Coffee Beans; Compressed Gases; Raw Grains; Raw Nuts/Seeds/Coconut; Raw earthen materials (e.g., unprocessed materials mined from the earth); Alcoholic Substances (Spirits, Liquors) Kraft Audit 3 rd Party SQE or 1 Certifications 1 Certifications or 3 rd Party SQE + Supplier Food Safety Assessment (frequency determined by Food Safety Group) 3 rd Party SQE or 1 Certifications Audits may be required as result of a risk assessment by BU or Plant using the material 2 3 NA 21

22 Kraft Foods Audit Matrix (Revised 11 May 2012) 1. Certifications include GFSI, i.e. (SQF 2000 Level 2 or 3, BRC version 5, IFS version 5, FSSC22000) Not Accepted: a) ISO22000 audits without PAS220; b) GMA-SAFE dated after December 31, 2011; c) Dutch HACCP issued after January 1, 2012; d) ISO PAS220 after January 1, 2012 Note: ISO22000+PAS220 is acceptable only if the supplier has their FSSC22000 audit scheduled during the next cycle 2. Primary Packaging (BRC/IoP Global Packaging Standard; ISO 22000:2005 Food safety management systems ; SQE Packaging Requirements (SQE Manual); SQF Packaging Standard; EN Management of hygiene in the production of packaging for foodstuffs) 3. NSF Cook & Thurber and Silliker audits accepted only for raw meat & raw meat products until further notice 4. Flour mills - AIB accepted for only until further notice; SQE or GFSI in Asia Pacific 5. Where local regulatory considerations make a higher tier rating necessary, this must be documented in local procedures, and notification sent to auditing, a lower tier rating cannot be applied. 6. Chemical Audit - Preference = Supplier achieves GFSI certification; Kraft Food Chemical audit is least preferred option but the materials should meet the chemical questionnaire requirements, typically materials derived from distilled and/or extraction processes., and permission by KFE-CEEMA Section Manager Auditing 7. Pharma Audit - Audits performed by approved 3 rd party Pharmacy auditors and companies, Certification by internationally recognized governmental agencies 22

23 Kraft Foods Audit/Inspection requirements Why GFSI Certification? There is only one true internationally recognized certification for food plants Food Safety Management Systems That is GFSI (Global Food Safety Initiative) approved certifications Launched in members in 150 countries Mission: Continuous improvement in FSMS to ensure confidence in the delivery of safe food products to consumers Objective: Convergence between food safety standards SQF 2000 Level 2 or 3, BRC version 5, IFS version 5, FSSC22000 all recognized, check for correct versions! 23 FSSC22000 preferred for Kraft Foods Internal plants The scheme owner is an independent, not for profit foundation System based vs. checklist like other schemes Is consistent in structure with Kraft QCMS/HACCP management systems Major customers and peer companies support (Wal-Mart, Safeway, Unilever, Nestle, Danone, Coca Cola)

24 Audit process flow Audit target list Assign tier rating Finalise target list Schedule audits Send out communication Confirm audit date Carry out audit Supplier approved Escalation for disapproved suppliers Tier 1 & 2 suppliers require Kraft SQE audit Tier 4 suppliers GFSI certification or 3 rd party SQE audit Procurement and Auditing team review plan Auditing send mail to suppliers to schedule Audit completed /certification confirmed Broker/Distributor/ Trader work with supplier to resolve issue or stop sourcing 24

25 On-boarding process for new Supplier B/D/T notifies Kraft Foods Contract Representative of potential new supplier Kraft checks status of supplier B/D/T sends Quality documents to supplier Yes Approved? No Tier 1 or 2 Tier 4 Tier 5 Kraft performs risk assessment Audit is performed No Does the supplier have any of following certifications: SQF 2000 Level 2 or 3, BRC version 5, IFS version 5, FSSC22000 Yes No Audit is required Approved? No Corrective actions may include follow-up audit c.a. Applied? Yes Yes Supplier in Approved Supplier list No Supplier in Disapproved Supplier list 25

26 On-going audit process for Suppliers Re-approval of Supplier Required Kraft Foods Audit team notifies Supplier that audit necessary Kraft Foods Audit team notifies B/D/T that audit necessary B/D/T sends Quality documents to supplier Tier 1 Tier 2, 4 Tier 5 Kraft performs risk assessment Audit is performed No Does the supplier have any of following certifications: SQF 2000 Level 2 or 3, BRC version 5, IFS version 5, FSSC22000 Yes No Audit is required Approved? No Corrective actions may include follow-up audit c.a. Applied? Yes Yes No Supplier in Disapproved Supplier list 26 Supplier in Approved Supplier list

27 Supplier Disapproval Kraft Foods will notify the Broker/Distributor/Trader if one of their suppliers is no longer approved for supply to Kraft The Broker/Distributor/Trader must immediate stop supplying to Kraft Foods from the disapproved Supplier 27

28 28 Kraft Foods Supplier Quality Expectations (SQE)

29 SQE Why we need the Supplier Quality Expectations? The Supplier Quality Expectations are intended to help Kraft Foods meet this objective by making our quality standards clear. These expectations have been developed by Kraft Foods after a review of product defects, quality audits of manufacturing sites and a study of product retrievals throughout the food industry. This review led Kraft Foods to identify which programs, if executed well, would have helped to prevent product retrievals, consumer complaints, rework and plant downtime. Scope Ingredient, Commodity and Packaging Suppliers Brokers, Distributors and Traders 29

30 30 SQE: Basic Requirements

31 Supplier Quality Documents Overview The Supplier Quality Expectations (SQE) has six main chapters: Introduction Quality System Control Facility Environment Controls Production Process Controls Incident Management Packaging Requirements Each of these chapters contains a series of programs that the supplier must have in place. In order to make sure that the food is safe to consumption, the supplier has to be aligned with the 34 quality programs that are outlined on the SQE. All the programs are universal programs that are also required by other food quality certifications (BRC, IFS, FSSC 22000, etc.). For some of the programs, Kraft may request additionally specific requirements due to the nature of the product and/or to assure the protection of our brands. 31

32 Supplier Quality Documents Overview (cont.) Introduction Confidentiality Notifying Kraft foods of significant events Quality System Control: Contains 8 programs related to the management of the quality system Quality Management System Kraft Foods Audit requirements Internal Audits Regulatory Contacts Food Defense Laboratory requirements Calibration of equipment Corrective and preventive Actions 32

33 Supplier Quality Documents Overview (cont.) Facility Environment Controls Contains 10 programs that are required in order to avoid contamination of the product by the personnel, environment or the equipment. Good Manufacturing Practices (GMP) Personnel training Employee illness and Communicable disease Plant Structure Utilities Management Equipment design & Validation Equipment Maintenance Sanitation Pest Management Zoning Pathogen Environmental Monitoring 33

34 Supplier Quality Documents Overview (cont.) Production Process Controls: Contains 12 programs related to the controls during the whole production cycle: from the supplier base, incoming raw materials, controls during production, packing, storing and transportation of the final product. Specification Compliance and Contract review Hazard Analysis and Critical Control Points (HACCP) Incoming Material: Supplier Quality Management Incoming Materials; inspection and Testing Traceability Allergen Management Extraneous Matter Rework Label Control Weigh Control Material Packaging Storage and Transportation 34

35 Supplier Quality Documents Overview (cont.) Incident Management This chapter contains 3 programs related to the procures that must be in place to deal with non-conforming products, e.g. products that re not in accordance to the specification. Hold & Release Product retrieval Control and disposition of Non-Conforming Products Packaging This is a specific chapter for Packaging Suppliers. We recommend packaging suppliers to start reading the SQE by this chapter. The supplier can find on this chapter specific requirements for packaging suppliers and is also a clear description of the other programs that are applicable for the packaging suppliers. 35

36 36 SQE: Key Programs

37 Notifying Kraft Foods of Significant Events The Broker/Distributor/Trader is requested to notify Kraft Foods immediately in some situations, e.g.: Inability to deliver materials that meet Kraft Foods Specifications A positive pathogen result (in the lot or in similar products produced on the same line and/or direct contact surface swab), even if the specific lot is not sent to Kraft Foods. Systematic product quality defect or process control deviation which could lead to a voluntary or involuntary recall or withdrawal of a Kraft Foods finished product. Discovery of potentially defective or adulterated ingredients or packaging materials associated with product in distribution. Inadvertent release from Hold of any material produced for Kraft Foods. Continued on next page 37

38 Notifying Kraft Foods of Significant Events (cont.) Continued from previous page Event that leads the Supplier to suspect that a non-conformance exists in product already shipped to Kraft Foods. Product tampering or threat of tampering. Event or substance that could threaten product security. Notification by law enforcement or other authority of a potential product security event. Identification of an unlabeled allergen in material produced for Kraft Foods. Non-routine regulatory agency investigations, testing, sampling, reporting, or other contact or action with the potential to affect material produced for Kraft Foods. Kraft Foods does not need to be notified of routine inspections, unless the inspection reveals that material produced for Kraft Foods may not be in compliance with applicable law. 38

39 Kraft Foods Audit/Inspection Requirements All facilities producing materials for Kraft Foods must be approved by Kraft Foods The Supplier must allow Kraft Foods quality auditors or their representatives to enter and audit/inspect at reasonable times any establishment storing or supplying for Kraft Foods The audit/inspection may include review of records, processes, controls, equipment, and facilities. The audit/inspection shall not be extended to financial data, sales data, pricing data or personnel data Audit findings must be deemed acceptable by Kraft Foods to become or remain an approved Supplier 39

40 Regulatory Inspection and Contacts Requires documented procedures and designated, trained personnel in place for the management of Food Regulatory Agency inspections and contacts Duplicate samples must be taken by the supplier of any products for Kraft Foods that were sampled by a regulatory agency and the specific lot(s) sampled must be placed on hold. In the event a regulatory agency samples material produced for Kraft Foods, Kraft Foods shall be immediately contacted. 40

41 Food Defense Definition: Steps to safeguard the food supply against intentional acts (or the threat of an act), such as a mass contamination or product tampering. Designed to protect the supply chain from intentional contamination. Four basic requirements Program administration (documented plan, defined role & responsibilities, annual vulnerability assessment) Access control Background screening (subject to local law) Shipping and Receiving (monitor and verify the integrity of incoming and outgoing shipments) Mandatory for all Regions 41

42 Specifications Compliance & Contract Review All materials supplied to Kraft Foods must meet Kraft Foods specifications. The Broker/Distributor/Trader must supply the latest version of the specification to supplier and record acknowledgment of receipt. Suppliers must notify Kraft Foods if a material that does not meet specifications is advertently shipped to Kraft Foods. Where Certificates of Analysis (COA) are part of the Specification requirements or have been separately requested by the Kraft Foods receiving plant, these must be provided to Kraft Foods prior to acceptance of the material at Kraft Foods locations. The Supplier shall notify the Kraft Foods receiving location if a lot is split between two or more Kraft Foods locations. 42

43 HACCP (Hazard Analysis Critical Control Point) HACCP is a risk-based, preventative food safety program. HACCP is a requirement for all quality systems in the food industry. HACCP programs primarily address three categories of Food Safety Hazards: Biological (microbiological pathogens) Chemical (allergens, additives, cleaners, sanitizers, pesticides, etc.) Physical (sharp, hard objects like metal, glass, hard plastic, etc.) The Kraft Foods Supplier HACCP Manual was developed to assist suppliers in understanding Kraft Foods HACCP requirements and to assist in the development of sound HACCP programs. 43

44 44 Recent events reported

45 HACCP (Hazard Analysis Critical Control Point) (cont.) Key Points The Supplier s products shall be designed, produced, and distributed using HACCP principles to minimize food safety risks systematically. The Supplier shall have implemented a written HACCP plan for all materials produced for Kraft Foods. The Supplier must validate their process in order to guarantee that it achieves the objectives against the pathogen microorganisms (e.g. Is the pasteurization effective? Is the roaster process effective? Does it always kill the microorganisms that could cause harm?). The validation report will be reviewed by Kraft Auditors/Microbiologist and must be available before the audit (when requested). If the Supplier has questions on how to perform this validation, please contact your quality support. 45

46 Allergen Management All allergens present in the product must be declared on the Kraft Foods label. The supplier has to assure that no undeclared allergen is present on the product. Undeclared allergens may be present trough cross contamination in the production plant (e.g. poor cleaning on the line). Effective systems shall be in place to prevent cross contamination between allergen containing products and other products/handled on site Examples of Allergens Allergens that must be controlled are listed in the HACCP Manual Milk, Eggs, Wheat, Fish, Peanuts, Sesame seeds, Soybean, and Tree nuts (Almonds, Brazil Nut, Cashew, Hazelnut, Macadamia Nut, Pine Nuts, Pistachio, Pecan, Walnut) 46

47 Traceability The Supplier shall have implemented a written program for product traceability, assuring that package and pallet, lot codes, and date information are accurate and consistent across similar businesses and products. Traceability requirements apply to all finished products and all components used to produce products, including ingredients, in-process products, rework, primary packaging materials, and/or process intermediated being shipped to Kraft Foods. If requested, such as in the event of a product recall or other productrelated issue, the Supplier must provide the relevant traceability information to Kraft Foods within 4 hours. Mock recalls shall be conducted at least once a year to validate the effectiveness of the traceability program. 47

48 Product Hold/Release Suppliers must have effective controls in place to prevent the inadvertent movement of defective products or ingredients. The Supplier shall have a written Hold and Release control program that clearly establishes roles and responsibilities for effective implementation. The program shall include controls for; non-conforming raw materials, materials pending testing, packaging and labels, semi-finished product (work-in-progress), rework and finished product. 48

49 Summary Compulsory for Traders, Distributors and Brokers 49 The Broker/Distributor/Trader must ensure that any materials delivered to Kraft Foods are produced in a Manufacturing site approved by Kraft Foods and according to approved Kraft Foods Specifications. Brokers, Distributors and Traders must ensure all Kraft Foods Supplier Quality Documents are communicated to all their suppliers supplying to Kraft Foods and provide evidence of the communication to Kraft Foods. The Broker/Distributor/Trader is required to notify Kraft Foods Contract Representative of any manufacturing location changes. New sites must be approved by Kraft Foods prior to use The Kraft Foods supplier approval process is ongoing. At regular defined intervals supplier must be reapproved by Kraft Foods. Kraft Foods will notify the Broker/Distributor/Trader if one of their suppliers is no longer approved for supply to Kraft and The Broker/Distributor/Trader must immediate stop supplying to Kraft Foods from the disapproved Supplier The Broker/Distributor/Trader should work with their suppliers to ensure that they, the Broker/Distributor/Trader, are able to meet their contractual obligations to Kraft Foods. Goods for Kraft shall be stored and handled at the Brokers/Distributors/ Traders warehouses under sanitary conditions (GWP = Good Warehousing Practices shall be applied).

50 Kraft Foods Supplier Quality Web Site The Kraft Foods Supplier Quality web site is designed to facilitate the communication between Kraft Foods and our suppliers. Here you will find all of the Quality Requirements and Guidelines for Suppliers to Kraft Foods, as well as the slides used in our Supplier Forums. The web site includes: Supplier Quality and Food Safety Contractual Requirements Supplier Forum presentations Quality Support Material Contact address elearning modules Browser Address: 50

51 Kraft Foods Supplier Quality Web Site e-learning Producing safe, consistent quality product is key to maintaining the trust and confidence of our customers and consumers elearning modules intended to build awareness of Food Safety and Quality programs and practices Kraft Foods is providing the elearning modules as a free, accessible (web-based) tool for our Suppliers in order to provide basic Quality and Food Safety training opportunities 12 modules covering: Cleaning & Sanitation, Allergen Control, Microbiological Hazard Control, GMPs, HACCP, Hold & Release Requirements, Design Safety Analysis, Internal Auditing, and Religious Food Law 51

52 52 Visit the Kraft Foods Supplier Quality and Food Safety web site at:

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